Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D4/00—Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
  • C09D4/06—Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D133/04—Homopolymers or copolymers of esters
  • C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
  • C09D133/08—Homopolymers or copolymers of acrylic acid esters
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D133/04—Homopolymers or copolymers of esters
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
  • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
  • C08F220/04—Acids; Metal salts or ammonium salts thereof
  • C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
  • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
  • C08F220/10—Esters
  • C08F220/12—Esters of monohydric alcohols or phenols
  • C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
  • C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
  • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
  • C08F220/10—Esters
  • C08F220/12—Esters of monohydric alcohols or phenols
  • C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
  • C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
  • C08F220/1804—C4-(meth)acrylate, e.g. butyl (meth)acrylate, isobutyl (meth)acrylate or tert-butyl (meth)acrylate
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
  • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
  • C08F220/10—Esters
  • C08F220/34—Esters containing nitrogen, e.g. N,N-dimethylaminoethyl (meth)acrylate
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/02—Elements
  • C08K3/04—Carbon
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
  • C09D133/02—Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• • G—PHYSICS
  • G10—MUSICAL INSTRUMENTS; ACOUSTICS
  • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
  • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
  • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
  • G10K11/162—Selection of materials
• • C08K3/0033—
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
  • C08K3/013—Fillers, pigments or reinforcing additives
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2201/00—Properties
  • C08L2201/56—Non-aqueous solutions or dispersions

Definitions

• the invention relates to a nonaqueous sound deadener composition
• a nonaqueous sound deadener composition comprising (a) a nonpulverulent polyacrylate binder having a K value in the range from 10 to 35, measured as a 1% strength solution in tetrahydrofuran; (b) inorganic fillers; and a radically polymerizable compound which has at least one radically polymerizable C—C double bond and possesses a boiling point at atmospheric pressure of greater than 160° C.
• the invention also relates to a method for damping oscillations or vibrations of components of vehicles and machines.
• the polyacrylate binders can be used as a raw material for producing coating compositions for automaking, for example, that are suitable for damping noise and vibration.
• this technology allows the vehicle manufacturer to achieve a weight saving, on the basis of the higher damping efficiency of sprayable systems. Also possible is a reduction in costs for personnel, logistics, and warehousing, with an attendant reduction in the space taken up and the dust burden arising on the production line.
• LASD compositions of this kind comprise not only fillers, which serve for reducing costs and for enhancing damping, but also polymeric fractions. Depending on the form in which they are present, these systems can be divided into aqueous and nonaqueous LASD systems.
• the polymeric fraction of aqueous LASD compositions is based chiefly on polyacrylate dispersions.
• the polyacrylate first fulfills the function of the binder, and also ensures the desired damping properties through copolymerization, with styrene or vinyl acetate, for example, or through mixing with other polymers, such as polyurethane, PVC plastisol, silicones or epoxide polymers, for example.
• dispersions allow a low viscosity in tandem with high solids contents and pseudoplastic behavior on the part of the LASD compositions. This enables spray application at high shearing rates, while in the resting state the composition retains dimensional stability, without flowing.
• the polymeric fraction of nonaqueous LASD compositions is very often based on rubbers, epoxy resins, PVC plastisols, polyurethanes or acrylate powders.
• the compositions on this basis become fluid by virtue of the melting of the polymers, and are applied to the substrate by subsequent spraying.
• Compositions which can be applied at room temperature often include plasticizers or low-viscosity binders to allow their processing. These variants require subsequent crosslinking with, for example, epoxidized silanes, peroxides, or reaction to polyurethanes, in order to obtain sufficient dimensional stability.
• Nonaqueous LASD compositions have the advantage that in the drying stages of the coating plant they usually solidify more rapidly and do not, as with the aqueous LASD compositions, generate water vapor, which can lead to unwanted cracking and blistering. Moreover, nonaqueous LASD compositions exhibit good stability toward moisture, and a high abrasion resistance.
• PVC plastisols have the disadvantage that they contain chlorine, a factor which is frequently undesirable.
• acrylate powders are generally prepared by emulsion polymerization followed by spray drying, and the emulsifiers used for the emulsion polymerization may remain in the polymer powders and migrate to the surface following application, and may detract from the adhesion of the damping composition to the metal.
• Acrylate plastisols furthermore, comprise a large amount of plasticizer relative to the mass of solids, and the plasticizer makes no contribution to the damping effect. The result is a relatively low damping effect per unit mass.
• Aqueous LASD compositions based on acrylate dispersions are notable for good damping qualities.
• Aqueous systems are described in EP 1935941, for example.
• Vibration-damping compositions based on waterborne polymer dispersions and inorganic fillers and also further auxiliaries are known from EP 1520865, WO 2007/034933, WO 01/90264, DE 10 2006 052 282, EP 2420412, and US2012/027941.
• An improvement in damping efficiency gives the automakers the possibility to realize a weight saving in comparison to bitumen mats and nonaqueous LASD compositions.
• the good toxicological properties of dispersions mean that they are not hampered by safety concerns, and can be processed without additional protective equipment.
• a disadvantage in the case of applied and dried compositions is a high water absorption, which can lead to an alteration in the properties and which jeopardizes the stability and long life of the applied and dried LASD compositions. Triggers for this tendency toward water absorption include capillary forces on the part of the porous composition, and also hydrophilic auxiliaries such as emulsifiers, dispersing assistants or stabilizers.
• Damping systems are used not only in the vehicle interior but also in the exterior area, such as wheel housings, engine compartment or cold box. These areas are subject to high humidity. The vibration-damping systems used there thus need to have a high resistance toward water absorption. Consequently, these areas have hitherto been inaccessible to water-based LASD compositions.
• Bitumen compositions though offering very low water absorption, have a relatively poor damping effect relative to the applied weight. Also known are water-free, sprayable systems based on rubber compositions. These compositions, however, have to be vulcanized with sulfur, and this may lead to odor problems.
• compositions may lift from the bodywork and fail to achieve sufficient vibration damping as a result of inadequate contact with the surface.
• WO 2011/174611 describes nonaqueous LASD compositions based on solvent-free polyacrylate binders. Because of the viscosity at room temperature, these compositions are still not ideally suitable for spraying applications.
• the object is to provide sound deadener compositions which are extremely good for spraying applications, having extremely low viscosities at room temperature, and at the same time exhibit an extremely broad damping value curve and extremely high damping values (based on application weight and solids content of the LASD compositions). Moreover, extremely good performance properties are to be achieved in respect of low water absorption on the part of applied LASD compositions, and also in relation to the problem of blistering and cracking in the drying tunnel.
• One preferred use for the sound deadener composition of the invention is for vibration damping of bodywork parts of a vehicle.
• nonaqueous means more particularly that no aqueous polymer dispersions are used in preparing the sound deadener compositions.
• the sound deadener composition is preferably solvent-free or of low solvent content in the sense that it constitutes a system of the kind known as “100% systems”, where the polymeric binder is used in bulk, in other words not in solution in a low-boiling, volatile organic solvent, or in the sense that low-boiling, volatile organic solvents are present only in small amounts of, for example, in total not more than 5% by weight or not more than 1% by weight and more preferably not more than 0.1% by weight.
• Low-boiling organic solvents are organic solvents having a boiling point at atmospheric pressure (1013 mbar) of less than 120° C.
• Polyacrylate binders are binders based on polymers which are composed predominantly, i.e., to an extent of more than 50% by weight, of (meth)acrylic esters.
• the expression “(meth)acryl . . . ” is an abbreviated notation for “acryl . . . or methacryl . . . ”.
• the polyacrylate binders for use in accordance with the invention are polymers having comparatively low, limited molecular weights, and are fluid at least on gentle heating and have a sufficiently low viscosity to allow them to be applied effectively to the substrates that are to be coated.
• One measure of the molecular weights is the K value (Fikentscher constant).
• the K value also referred to as intrinsic viscosity, is a parameter which is easily determined via viscosity measurements of polymer solutions, and under standardized measurement conditions is solely dependent on the average molar mass of the sample under analysis.
• the K values of the polyacrylate binders are in the range from 10 to 35, preferably 10 to 25, measured as a 1% strength solution in tetrahydrofuran at 21° C.
• the glass transition temperature (Tg) of the polyacrylate binder is preferably ⁇ 60 to +80° C., more preferably from ⁇ 30 to less than or equal to +60° C.
• the glass transition temperature can be determined by customary methods such as Differential Scanning calorimetry (ASTM 3418-08, the midpoint temperature). The nature and amount of the monomers are such that the glass transition temperature of the polyacrylate binder lies within the specified range.
• the zero-shear viscosity of the polyacrylate binder at 130° C. is preferably not more than 40 Pa s, or not more than 20 Pa s, or not more than 10 Pa s, e.g., 1 to 40 Pa s or 1 to 20 Pa s or 1 to 10 Pa s.
• Preferred polyacrylate binders are obtainable by polymerization of radically polymerizable acrylate monomers, a term which is understood to include methacrylate monomers, and optionally further, copolymerizable monomers.
• the polymers are formed preferably to an extent of at least 60%, very preferably at least 80%, by weight from C 1 to C 10 alkyl (meth)acrylates and optionally from further monomers. Mention may be made more particularly as (meth)acrylate monomers of C1-C8 alkyl (meth)acrylates, examples being methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, and 2-ethylhexyl (meth)acrylate.
• the alkyl (meth)acrylates preferably also comprise polyethylenically unsaturated, radically polymerizable monomers, more particularly those monomers which have further acrylic or nonacrylic, crosslinkable C—C double bonds (crosslinkable groups for short).
• Crosslinkable double bonds are more particularly those which are radically polymerizable with other double bonds (that is, which crosslink by radical polymerization), or those which form radicals by elimination of a hydrogen atom (in other words, which crosslink by reactions of these radicals).
• Examples of crosslinkable groups contemplated include the allyl group or cyclic hydrocarbon groups having at least one nonaromatic C—C double bond.
• the cyclic hydrocarbon group is more particularly a dihydrodicyclopentadienyl group of the formula:
• Examples include allyl (meth)acrylate, butanediol di(meth)acrylate, or monomers having a (meth)acryloyl group and a dihydrodicyclopentadienyl group.
• the (meth)acryloyl group may be bonded directly or indirectly, in other words via an organic group as spacer, to the dihydrodicyclopentadienyl group; preference is given to dihydrodicyclopentadienyl (meth)acrylate of the following formulae:
• Monomers which as well as the first acrylic double bond also carry a further ethylenic double bond, preferably a nonacrylic bond, are able to improve the connection between the polyacrylate binder and the radical polymerizable compound in the course of curing (drying) and hence to improve the damping efficiency of the damping compound.
• nonacrylate monomers of which the polyacrylate binder may additionally be composed are, for example, vinyl esters of carboxylic acids comprising up to 20 C atoms, vinylaromatics having up to 20 C atoms, ethylenically unsaturated nitriles, vinyl halides, vinyl ethers of alcohols comprising 1 to 10 C atoms, aliphatic hydrocarbons having 2 to 8 C atoms and 1 or 2 double bonds, or mixtures of these monomers.
• vinylaromatic compounds contemplated include vinyltoluene, ⁇ - and p-methylstyrene, alpha-butylstyrene, 4-n-butylstyrene, 4-n-decylstyrene, and preferably styrene.
• nitriles are acrylonitrile and methacrylonitrile.
• the vinyl halides are chlorine-, fluorine- or bromine-substituted ethylenically unsaturated compounds, preferably vinyl chloride and vinylidene chloride.
• vinyl ethers include vinyl methyl ether and vinyl isobutyl ether.
• Preferred vinyl ethers are those of alcohols comprising 1 to 4 C atoms. Hydrocarbons having 2 to 8 C atoms and two olefinic double bonds include butadiene, isoprene, and chloroprene.
• Further monomers contemplated also include, in particular, ethylenically unsaturated, radically polymerizable acid monomers, examples being monomers having carboxylic, sulfonic or phosphonic acid groups.
• Carboxylic acid groups are preferred. Examples include acrylic acid, methacrylic acid, itaconic acid, maleic acid, and fumaric acid.
• Further monomers are also, for example, (meth)acrylamide and monomers comprising hydroxyl groups, especially C1-C10 hydroxyalkyl (meth)acrylates.
• Monomers which in addition to the double bond also carry further functional groups, e.g., isocyanate-, amino-, hydroxy-, amide- or glycidyl-, may have the effect, for example, of improving the adhesion to substrates.
• the further monomers are preferably selected from ethylenically unsaturated, radically polymerizable acid monomers, vinyl esters of carboxylic acids comprising up to 20 C atoms, vinylaromatics having up to 20 C atoms, ethylenically unsaturated nitriles, vinyl halides, vinyl ethers of alcohols comprising 1 to 10 C atoms, aliphatic hydrocarbons having 2 to 8 C atoms and one or two double bonds, or mixtures of these monomers.
• the polyacrylate binders may be prepared by copolymerizing the monomeric components using the customary polymerization initiators and also, optionally, regulators, and carrying out polymerization at the customary temperatures in bulk, in emulsion, e.g., in water or liquid hydrocarbons, or in solution. It is preferred to prepare the polyacrylate binders by polymerizing the monomers in organic solvents, more particularly in organic solvents having a boiling range of 50 to 150° C., preferably of 60 to 120° C., using the customary amounts of polymerization initiators, this being generally 0.01% to 10%, more particularly 0.1% to 4%, by weight, based on the total weight of the monomers.
• the copolymers can be prepared at temperatures of 20 to 150° C., preferably at temperatures in the range from 70 to 120° C., and at pressures of 0.1 to 100 bar (absolute), preferably at 0.3 to 10 bar, in the presence of 0.01% to 10% by weight of peroxides or azo compounds as polymerization initiators, based on the monomers, and in the presence of 0% to 200% by weight of inert solvents, preferably of 5% to 25% by weight, based on the monomers, i.e., by solution polymerization or bulk polymerization.
• the reaction takes place preferably under increasingly reduced pressure, as for example by lowering of the pressure from atmospheric pressure (1 bar) to 500 mbar (absolute).
• solvents examples include hydrocarbons such as toluene or o-xylene, alcohols such as methanol, ethanol, propanol, butanol, and isobutanol, ketones such as acetone, methyl ethyl ketone and methyl isobutyl ketone, ethyl acetate, nitriles such as acetonitrile and benzonitrile, or mixtures of the stated solvents.
• hydrocarbons such as toluene or o-xylene
• alcohols such as methanol, ethanol, propanol, butanol, and isobutanol
• ketones such as acetone, methyl ethyl ketone and methyl isobutyl ketone
• ethyl acetate examples of solvents.
• polymerization initiators contemplated include azo compounds, ketone peroxides, and alkyl peroxides, examples being acyl peroxides such as benzoyl peroxide, dilauroyl peroxide, didecanoyl peroxide, and isononanoyl peroxide, alkyl esters such as tert-butyl perpivalate, tert-butyl per-2-ethyl hexanoate, tert-butyl permaleate, tert-butyl perisononanoate, tert-butyl perbenzoate, and tert-amyl per-2-ethylhexanoate, dialkyl peroxides such as dicumyl peroxide, tert-butyl cumyl peroxide, and di-tert-butyl peroxide, and peroxodicarbonates.
• acyl peroxides such as benzoyl peroxide, dil
• azo starter compounds such as 2,2′-azobisisobutyronitrile, 2,2′-azobis(methyl isobutyrate) or 2,2′-azobis(2,4-dimethylvaleronitrile), for example.
• chain transfer agents compounds that lower the degree of polymerization
• suitable compounds are those having a thiol group, as for example mercaptans such as mercaptoethanol, tert-butyl mercaptan, mercaptosuccinic acid, ethylhexyl thioglycolate, 3-mercaptopropyltrimethoxysilane or dodecyl mercaptan.
• no chain transfer agents are used.
• the polyacrylate binder is preferably prepared
• a particularly preferred polyacrylate binder is prepared from methyl (meth)acrylate (preferably methyl methacrylate), at least one C2 to C4 alkyl acrylate (preferably n-butyl acrylate), (meth)acrylic acid (preferably acrylic acid), and (meth)acrylic esters with an additional, nonacrylic double bond (preferably dihydrodicyclopentadienyl acrylate), e.g.
• the acrylate binders In contrast to known acrylate plastisols there is no need for the acrylate binders to be polymer particles having a core-shell morphology; preferably, therefore, they do not have a core-shell morphology.
• the sound deadener composition of the invention comprises at least one radically polymerizable compound (c), which has at least one radically polymerizable C—C double bond and possesses a boiling point at atmospheric pressure of greater than 160° C., preferably greater than 180° C.
• This compound (c) acts like what is called a reactive diluent.
• a reactive diluent is a reactive dilution agent or a reactive solvent which is able to become part of the coating by chemical reaction in the course of film formation or drying. It may comprise monomers or oligomers having in each case one, two, three or more functionalities (C—C double bonds), examples being mono-, di- or tri(meth)acrylates, with oligomers being compounds composed preferably of 2 to 10 monomer units.
• the compounds (c) have precisely one radically polymerizable C—C double bond to an extent of 50% to 100% by weight, and have two or more radically polymerizable C—C double bonds to an extent of 0% to 50% by weight.
• Suitable compounds (c) are, for example, selected from (meth)acrylate monomers, vinyl ether monomers, (meth)acrylate oligomers, vinyl ether oligomers, mono-, di- or polyalkylene glycol diacrylates having preferably 1 to 6, more particularly 2 or 3, C atoms in the alkylene group, urethane acrylates, or a mixture thereof.
• the radically polymerizable compounds (c) have in the polymerized state preferably a glass transition temperature in the range from ⁇ 30 to +60° C.
• the composition preferably further comprises at least one thermally activatable initiator. On increase in temperature, the initiator initiates a radical polymerization reaction.
• Suitable thermal initiators are those which find application in radical polymerization, such as, for example, azo compounds, ketone peroxides, and alkyl peroxides, examples being acyl peroxides such as benzoyl peroxide, dilauroyl peroxide, didecanoyl peroxide, and isononanoyl peroxide, alkyl esters such as tert-butyl perpivalate, tert-butyl per-2-ethylhexanoate, tert-butyl permaleate, tert-butyl perisononanoate, tert-butyl perbenzoate, and tert-amyl per-2-ethylhexanoate, dialkyl peroxides such as dicumyl peroxide, tert-butyl cumyl peroxide, 1,1-di(tert-butylperoxy)-3,3,5-trimethylcyclohexane, di-ter
• azo starter compounds such as 2,2′-azobisisobutyronitrile, 2,2′-azobis(methyl isobutyrate) or 2,2′-azobis(2,4-dimethylvaleronitrile), for example.
• Preferred initiators are those which have a half-life of greater than or equal to one hour at 100° C.
• Very preferred initiators are those provided on an inorganic support, an example being 1,1-di(tert-butylperoxy)-3,3,5-trimethylcyclohexane, powder, 40% on calcium carbonate and silica.
• thermal initiator are 0.01% to 10% by weight, based on the sound deadener composition, more preferably from 0.1% to 5% by weight.
• the sound deadener composition may comprise at least one nonreactive, inert organic film-forming assistant which is liquid at room temperature (20° C.) and has a boiling point of greater than 160° C.
• suitable film-forming assistants are ethylene glycol, polyethylene glycols, ethylene glycol alkyl ethers (e.g., Cellosolve® products), diethylene glycol alkyl ethers (e.g., Carbitol® products), carbitol acetate, butyl carbitol acetate, hydrocarbons, or mixtures thereof; polypropylene glycol esters, polypropylene glycol ethers; and plasticizers such as esters of cyclohexanedicarboxylic acid and phthalic esters.
• Preferred film-forming assistants with high boiling point have a low viscosity at room temperature (20° C.), preferably of less than 50 mPa s.
• Preferred film-forming assistants are polyethylene glycol, oligopropylene glycol esters or oligopropylene glycol ethers having a boiling point of greater than 160° C., where “oligo” stands for 2 to 10 monomer units.
• the film-forming assistants with a boiling point at atmospheric pressure of greater than 160° C. are preferably included in an amount of less than 20% by weight, as for example from 0% to less than 20% by weight or from 1% to less than 10% by weight, preferably not more than at 5% by weight or not more than at 1% by weight, and more preferably not more than at 0.1% by weight.
• Solvents having a boiling point at atmospheric pressure of less than 120° C. are preferably included in an amount of less than 10% by weight or less than 5% by weight, as for example from 0% to less than 10% by weight or from 0% to less than 5% by weight or from 1% to less than 10% by weight or from 1% to less than 5% by weight.
• Suitable solvents with boiling point of less than 120° C. are, for example, acetone, methyl ethyl ketone, and lower alcohols having preferably 1 to 4 C atoms such as methanol, ethanol, n-propanol, and isopropanol.
• the sound deadener composition of the invention is preferably solvent-free, meaning that it comprises no organic solvents—or at any rate less than 1% by weight or less than 0.1% by weight of such solvents—with a boiling point of less than 120° C.
• the sound deadener composition of the invention comprises preferably
• film-forming assistants preference is given to using 0.3 to 60 parts by weight or 3 to 25 parts by weight of film-forming assistants per 100 parts by weight of polyacrylate binder.
• suitable inorganic fillers include calcium carbonate, kaolin, mica, silica, chalk, microdolomite, finely ground quartz, talc, clay, barium sulfate, alumina, iron oxide, titanium dioxide, glass powders, glass flakes, magnesium carbonate, aluminum hydroxide, bentonite, fly ash, kieselguhr, perlite, and mica. It is preferred to use flakelike fillers such as mica, for example, alone or in combination with typical inorganic pigments such as calcium carbonate, kaolin, silica or talc. Preferred fillers are kaolin, chalk, barium sulfate, carbon black, graphite, talc, clay minerals, microdolomite, finely ground quartz, and mica.
• inorganic filler it is preferred to use 50 to 700 or 100 to 600 parts by weight of inorganic filler to 100 parts by weight of polyacrylate binder, and preferably 30 to 150 or 40 to 120 parts by weight of flakelike fillers are used per 100 parts by weight of polyacrylate binder.
• auxiliaries which are used preferably to an extent of at least 0.1% by weight, from 0.2% to 5% by weight for example, include crosslinkers, thickeners, rheological additives, resins, plasticizers, organic and inorganic pigments, stabilizers, wetting agents, preservatives, foam inhibitors, glass or plastics beads, hollow glass or plastics bodies, antifreeze agents, dispersants, antioxidants, UV absorbers, antistats, and pigment dispersants.
• one, two or a plurality may be used in combination.
• thickeners are polyvinyl alcohols, cellulose derivatives or polyacrylic acids, in amounts of, for example, 0.01 to 4 or of 0.05 to 1.5 or of 0.1 to 1 parts by weight, based on 100 parts by weight of solids.
• dispersants are sodium hexametaphosphate, sodium tripolyphosphates, or polycarboxylic acids.
• antifreeze agents are ethylene glycol or propylene glycol.
• foam inhibitors include silicones.
• stabilizers are polyvalent metal compounds such as zinc oxide, zinc chloride or zinc sulfate.
• the auxiliaries are preferably used at not less than 0.1% by weight and are preferably selected from crosslinkers, thickeners, rheological additives, resins, plasticizers, defoamers, preservatives, antifreeze agents, and pigment dispersants.
• the quality of sound deadener composition can be measured by measurement of the flexural vibrations by the resonance curve method in accordance with ISO 6721-1 and ISO 6721-3.
• One measure of the vibration-damping effect is the loss factor tan delta.
• the maximum value of the loss factor tan delta is situated preferably in the range from ⁇ 20 to +70° C. Where two or more different binders are used, there are generally two or more maxima to the loss factor, at not less than two different temperatures. In this case it is preferred for all of the maxima of the loss factor to be situated within the range from ⁇ 20 to +70° C. Where crosslinkers are used, the values relate to the crosslinked sound deadener composition.
• the invention also provides a method for damping oscillations or vibrations of components of vehicles or machines, by
• Application may take place in a usual way, as for example by brushing, rolling or spraying.
• the amount applied is preferably from 1 to 7 kg/m 2 or from 2 to 6 kg/m 2 after drying. Drying may take place at ambient temperature or, preferably, by application of heat.
• the drying temperatures are preferably from 80 to 210° C. or from 90 to 180° C. or from 120 to 170° C.
• the sound deadener composition may be employed, for example, in vehicles of all kinds, more particularly road-going motor vehicles, automobiles, and rail vehicles, but also in boats, aircraft, electrical machines, construction machines, and buildings.
• the invention also provides a substrate at least partly coated with a sound deadener composition as described above.
• the sound deadener compositions of the invention have good performance properties in terms of good application qualities, including spray applications, and good vibration-damping qualities, and are notable for a low water absorption capacity and for avoidance of blistering.
• Laromer ® LR 8887 monofunctional reactive diluent comprising trimethylolpropane formal acrylate Laromer ® LR 8907 reactive diluent, polyester acrylate comprising dipropylene glycol diacrylate Genomer ® 1122 reactive diluent, comprising monofunctional urethane acrylate Trigonox ® 17-40b-pd butyl 4,4-di(tert-butylperoxy)valerate Trigonox ® 29-40B-pd 1,1-di(tert-butylperoxy)-3,3,5- trimethylcyclohexane
• a Hausschild DAC 400FVZ SpeedMixer is used. This is a rotary mixer which mixes the samples thoroughly without incorporation of air.
• the rotary speed can be set within a range from 800 to 2750 1/min.
• the apparatus consists of a stirring mechanism, a shaft driven by the mechanism, and a dissolver disk as stirring tool. With this form of mixing, air is incorporated into the sample.
• the stirring speed can be set in the range of 0-1000 1/min.
• the dissolver disk is a disk with teeth on its periphery, of the kind known to the expert for the dispersing of resins, for example, in water in the paints and coatings industry.
• the K value is measured on a 1% by weight strength solution in THF at 21° C.
• the viscosity measurement is made using a capillary viscometer.
• the K value is calculated according to the Fikentscher equation from the relative viscosity ⁇ r :
• a polymerization apparatus made up of glass reactor, reflux condenser, stirrer, and nitrogen inlet is charged under a gentle stream of nitrogen with 484.1 g of o-xylene, and this initial charge is heated to 140° C.
• 40 g of a monomer mixture made up of 456 g of n-butyl acrylate, 160 g methyl methacrylate, 64 g of acrylic acid, and 120 g of dihydrodicyclopentadienyl acrylate are added.
• an initiator solution consisting of 10.7 g of tert-butyl perpivalate (75% strength in mineral oil) and 80 g of o-xylene are added, and polymerization is commenced for 3 minutes. Then the remaining 760 g of monomer mixture and 86 g of initiator solution are run in over 3 hours. 15 minutes after the end of the feed, a solution of 2.56 g of tert-butyl perpivalate (75% strength in mineral oil) in 40 g of o-xylene is added over 30 minutes. Thereafter, reduced pressure is applied, and the solvent is removed by distillation at not more than 140° C. and ⁇ 50 mbar. This is followed by degassing with slow stirring for 1 hour at 140° C. and optimum vacuum.
• a polymerization apparatus made up of glass reactor, reflux condenser, stirrer, and nitrogen inlet is charged under a gentle stream of nitrogen with 1104 g of MEK, and this initial charge is heated to 80° C. 25 g of a monomer mixture made up of 300 g of n-butyl acrylate, 160 g of methyl methacrylate, 25 g of acrylic acid, and 15 g of dihydrodicyclopentadienyl acrylate are added. When 80° C. have been regained, 2.8 g of an initiator solution consisting of 6.7 g of tert-butyl perpivalate (75% strength in mineral oil) and 50 g of MEK are added, and polymerization is commenced for 3 minutes.
• a polymerization apparatus made up of glass reactor, reflux condenser, stirrer, and nitrogen inlet is charged under a gentle stream of nitrogen with 860 g of o-xylene, and this initial charge is heated to 140° C.
• 50 g of a monomer mixture made up of 600 g of n-butyl acrylate, 330 g of methyl methacrylate, 50 g of acrylic acid, and 20 g of dihydrodicyclopentadienyl acrylate are added.
• an initiator solution consisting of 13.3 g of tert-butyl perpivalate (75% strength in mineral oil) and 100 g of o-xylene are added, and polymerization is commenced for 3 minutes. Then the remaining 950 g of monomer mixture and 107.7 g of initiator solution are run in over 3 hours. 15 minutes after the end of the feed, a solution of 3.2 g of tert-butyl perpivalate (75% strength in mineral oil) in 50 g of o-xylene is added over 30 minutes. Thereafter, reduced pressure is applied, and the solvent is removed by distillation at not more than 140° C. and ⁇ 50 mbar. This is followed by degassing with slow stirring for 1 hour at 140° C. and optimum vacuum.
• a polymerization apparatus made up of glass reactor, reflux condenser, stirrer, and nitrogen inlet is charged under a gentle stream of nitrogen with 602 g of o-xylene, and this initial charge is heated to 140° C.
• 35 g of a monomer mixture made up of 399 g of n-butyl acrylate, 119 g of methyl methacrylate, 105 g of styrene, 56 g of acrylic acid, and 21 g of dihydrodicyclopentadienyl acrylate are added.
• a polymerization apparatus made up of glass reactor, reflux condenser, stirrer, and nitrogen inlet is charged under a gentle stream of nitrogen with 860 g of o-xylene, and this initial charge is heated to 140° C.
• 50 g of a monomer mixture made up of 600 g of n-butyl acrylate, 350 g of methyl methacrylate, and 50 g of acrylic acid, are added.
• an initiator solution consisting of 13.3 g of tert-butyl perpivalate (75% strength in mineral oil) and 100 g of o-xylene are added, and polymerization is commenced for 3 minutes.
• Example 6 Preparation of a Mixture of Low Molecular Mass Resin from Example 1 and Reactive Diluents (Laromer® LR 8887 and Laromer® LR 8907)
• the resin from example 1 is mixed at 80° C. in a dissolver-stirrer with the Laromers® LR 8887 and LR 8907 in a ratio of 50:40:10 (resin:LR8887:R8907). The mixture is subsequently homogenized in a Speedmixer at 2750 rpm for 1 minute.
• Example 7 Preparation of a Mixture of Low Molecular Mass Resin from Example 2 and Reactive Diluent (Laromer® LR 8887)
• the resin from example 2 is mixed at 80° C. in a dissolver-stirrer with the Laromer® LR 8887 in a ratio of 50:50 (resin:LR8887). The mixture is subsequently homogenized in a Speedmixer at 2750 rpm for 1 minute.
• Example 8 Preparation of a Mixture of Low Molecular Mass Resin from Example 3 and Reactive Diluent (Laromer® LR 8887)
• the resin from example 3 is mixed at 80° C. in a dissolver-stirrer with the Laromer® LR 8887 in a ratio of 50:50 (resin:LR8887). The mixture is subsequently homogenized in a Speedmixer at 2750 rpm for 1 minute.
• Example 9 Preparation of a Mixture of Low Molecular Mass Resin from Example 3 and Reactive Diluent (Genomer® 1122)
• the resin from example 3 is mixed at 80° C. in a dissolver-stirrer with the Genomer® 1122 in a ratio of 50:50 (resin: 1122). The mixture is subsequently homogenized in a Speedmixer at 2750 rpm for 1 minute.
• Example 10 Preparation of a Mixture of Low Molecular Mass Resin from Example 4 and Reactive Diluent (Laromer® LR 8887)
• the resin from example 4 is mixed at 80° C. in a dissolver-stirrer with the Laromer® LR 8887 in a ratio of 50:50 (resin:LR8887). The mixture is subsequently homogenized in a Speedmixer at 2750 rpm for 1 minute.
• Example 11 Preparation of a Mixture of Low Molecular Mass Resin from Example 5 and Reactive Diluent (Heptadecyl Acrylate)
• the resin from example 5 is mixed at 80° C. in a dissolver-stirrer with the heptadecyl acrylate in a ratio of 50:50 (resin:acrylate). The mixture is subsequently homogenized in a Speedmixer at 2750 rpm for 1 minute.
• the mixture from example 6 is admixed at 60° C. with 1% (based on the mixture) of initiator (Trigonox® 17-40b-pd) and subjected to mixing in a Speedmixer at 2750 rpm for 1 minute. Then barium sulfate (EWO) and chalk (Omyacarb® 15GU) (in equal weight fractions) are added to the binder (mixture 6) in a ratio of 80:20 (filler:binder), and this mixture is homogenized in a Speedmixer at 2750 rpm for 1 minute.
• initiator Trigonox® 17-40b-pd
• EWO barium sulfate
• chalk in equal weight fractions
• the mixtures from examples 7 to 11 are admixed at 60° C. with 1% (based on the mixture) of initiator (Trigonox® 29-40B-PD) and subjected to mixing in a Speedmixer at 2750 rpm for 1 minute. Then barium sulfate (EWO) and chalk (Omyacarb® 20BG) in equal weight fractions are added to the binder (mixtures from examples 7 to 11) in a ratio of 80:20 (filler:binder), and this mixture is homogenized in a Speedmixer at 2750 rpm for 1 minute.
• initiator Trigonox® 29-40B-PD
• a sheet steel test specimen with a size of 30 ⁇ 300 ⁇ 1.6 mm is coated with the sound deadener composition under test, which is dried at 160° C. for 30 minutes.
• the coating rate is approximately 3.0 kg per m 2 .
• the water absorption is determined in a method based on DIN EN ISO 62:2008. For this purpose, films with a thickness of approximately 2 mm and a side length each of 25 mm are produced from the sound deadener compositions prepared. The films are dried first at room temperature (20° C.) for 24 hours, then at 160° C. for 30 minutes, and are each stored for 24 during storage. This increase is determined gravimetrically using a Mettler Toledo AG204 analytical balance.
• the sound deadener composition in a thickness of 3 mm with an edge length of 60 mm ⁇ 100 mm is assessed visually after drying at 160° C. for 30 minutes.
• the rating scale used in this assessment is as follows:
• the zero-shear viscosity is the limiting value of the viscosity function at infinitely low shear rates. It is measured using an Anton Paar MCR 100 Rheometer (US 200 analysis software) in plate/plate geometry. The samples are measured in oscillatory shear with a low shear amplitude of 10%. Temperature 20°, 60° or 90° C. (as indicated), oscillating frequency ramp log 100-0.1 1/s, measurement slit 0.5 mm, evaluation by Carreau-Gahleitner I, die diameter 25 mm.

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